Prefabricated composite masonry panel formed of prelaid individual masonry modules bonded together



Apnl 23, 1968 G. K- LARGER 3,378,969

PREFABRICATED COMPOSITE MASONRY PANEL FORMED OF PRELAID INDIVIDUALMASONRY MODULES BONDED TOGETHER Filed Sept. 7, 1966 5 Sheets-Sheet lINVENTOR. GEORGE K. LARGER- BY MAHONEY, MILLER. 8 RAMBO ATTORNEYS v Apnl23, 1968 G. K LARGER 3,378,969

PREFABRICATEID COMPOSITE MASONRY PANEL FORMED OF PRELAID INDIVIDUALMASONRY MODULES BONDED TOGETHER Filed Sept. 7, 1966 5 Sheets-Sheet 2INVENTOR.

GEORGE K. LARGER v BY MA-IYONEY, MILLER a RAMBO 3.1 a.

I ATTORNEYS Aprll 23, 1968 G. K. LARGER 3,378,969

PREFABRICATED COMPOSITE MASONRY PANEL FORMED OF PRELAID INDIVIDUALMASONRY MODULES BONDED TOGETHER Filed Sept. 7. 1966 3 Sheets-Sheet s mmq GEORGE K. LARGER IO 4 BY 5.1 E MA /9MB, MILLER aRAMBo ATTORNEYS UnitedStates Patent 3,378,969 PREFABRICATED COMPOSITE MASONRY PANEL FORMED 0FPRELAID INDIVIDUAL MASONRY MODULES BONDED TOGETHER George K. Larger,2744 Gantz Road, Grove City, Ohio 43123 Filed Sept. 7, 1966, Ser. No.577,688 6 Claims. (Cl. 52-228) ABSTRACT OF THE DISCLOSURE A masonrypanel which is formed of individual masonry units or modules, such asconcrete blocks, bricks, tile or the like, that are bonded together in acomposite unitary panel. The panel is prefabricated of the masonry unitsat a factory or shop rather than on the job for economy and efiiciency.The panel can be fabricated by use of the block-laying machine disclosedin my co-pending application, Ser. No. 524,892, filed Feb. 3, 1966, nowPatent No. 3,350,833 issued Nov. 7, 1967, by other blocklaying machinesor by hand but it is preferably made by use of the machine disclosed insaid application.

General structure and advantages According to my present invention, thepanel comprises a Series of masonry modules or units laid in any of thestandard styles of horizontal courses set in a bonding material, such asmortar, between a lower clamping or supporting beam and an upperclamping or supporting beam which are joined together by verticallyextending tensile members or rods that extend through aligned verticalopenings in the various horizontal courses. The beams and cooperatingtensile rods not only serve to hold the courses together in assembledrelationship but the beams also serve as means for securing the panelsin position in a building structure. The beam members are so formed asto cooperate in securing adjacent panels together vertically insuperimposed, edgeto-edge, weathertight relationship, and the panelsalso preferably have means for securing in weathertight relationship theadjacent edges of panels disposed in side-by-side relationship.

Various other advantages of my invention will be apparent from thedrawings and the following description.

Brief description of drawings The accompanying drawings illustratepanels made according to my invention and the manner in which they maybe incorporated in various building structures but it is to beunderstood that this is by way of example only.

In these drawings:

FIGURE 1 is a perspective view of a panel embodying my invention.

FIGURE 2 is a horizontal sectional view taken along line 2-2 of FIGURE1.

FIGURE 3 is a vertical sectional view taken through a panel and showinganother panel positioned on its upper edge and secured in a buildingstructure.

FIGURE 3a is an enlarged horizontal sectional view taken on line 3a-3aof FIGURE 4.

FIGURE 4 is a fragmentary vertical sectional view showing a horizontaljoint between two panels disposed in superimposed edge-to-edgerelationship.

FIGURE 5 is an outer fragmentary face view, partly broken away, takenfrom the position indicated at line 5--5 of FIGURE 3 and showing detailsof the means for securing the panels in the building structure.

FIGURE 6 is a fragmentary horizontal sectional view taken along line 66of FIGURE 5 and showing details of the interlocking sealed joint betweenadjacent side edges of the panels made of concrete blocks.

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FIGURE 6a is a view similar to FIGURE 6 but showing the sealed jointbetween adjacent side edges of panels made of brick.

FIGURE 7 is a fragmentary plan view taken from the position indicated atline 7-7 of FIGURE 5 showing details of the means for securing thepanels in the building structure.

FIGURE 8 is a fragmentary vertical sectional view illustrating adifferent way of incorporating the panel in a building structure.

Detailed description of drawings With particular reference to thedrawings, the prefabricated panel of this invention is indicated best inFIG- URES 13. This panel is made as a composite unit and may be made ata factory or plant and then hauled to the job and erected as an integralunit. It is distinguished from the usual prefabricated masonry panelswhich are ordinarily made of a single casting of concrete or the like inthat it is formed of a series of masonry modules or units laid in any ofthe standard styles of courses. Thus, in the example shown in FIGURES1-3, the panel is shown made of masonry modules in the form of concreteblocks 10. These blocks are laid up with mortar joints 11 which may beof mortar of the type commonly used in laying concrete blocks or may beof other suitable bonding material. In the example shown, the blocks arelaid in horizontal courses with the vertical joints staggered but otherstyles may be used. To form the composite panel, the series ofvertically stacked horizontal courses are held in cooperativerelationship by clamping and supporting beams 12 which are disposed atthe upper and lower edges of the panel. These beams 12 are preferablyformed of steel and are mainly of channel shape, each being providedwith the inwardly directed channel portion 13 and the laterally directedouter flanges 14. The inwardly directed channel portions 13 provide ribswhich fit into the respective upper and lower courses of the blocks 10.There fore, each upper and lower course of blocks is grooved asindicated at 15 longitudinally on its outer edges to receive thelongitudinally extending ribs. To join the beams 12 into clampingrelationship to the series of block courses, tensile members 16 areprovided which are indicated as being in the form of steel rods andthese tensile members extend through the core openings 17 of therespective courses of blocks which are in alignment in the usual manner.The opposite ends of these rods 16 project through openings formed inthe channel portions 13 of the beam members 12 and have clamping nutsand washers 18 applied thereto. It will be noted from FIGURE 3 that theends of the rods 16 and the nuts thereon are recessed within therespective edges of the panel being disposed in the channels of themembers 12.

The beams 12 not only provide for clamping the courses of block togetherbut also provide means for securing the panels, which are indicatedgenerally by the numeral 20, in a building structure. For this purpose,the upper beam 12 is preferably provided with integral attaching lugs 21which extend outwardly from one of the clamping flanges 14 and which arelaterally spaced towards the side edges of the panel. These lugs are ofright angle form and are provided with horizontal and vertical portions.The vertical portion 22 of each is provided with a vertical slot 23. Asimilar single lug 21a is provided on the lower beam 12 midway of itsends and is of greater length than the lugs 21.

In using these attaching lugs 21 and 21a, as indicated in FIGURES 3 and3a, the vertical portions 22 may be attached to an angle member 24 in asuitable steel supporting frame structure, both at the upper and thelower ends of the panel 20. This attachment may be made by means ofclamping bolts 25 which are passed through the vertical slots 23 of thelugs 21 or 210. As indicated in FIGURES and 6, the angle member 24 inits upright flange may be provided with horizontal slots 26 forcooperating with the clamping bolts to permit horizontal adjustment asWell as the vertical adjustment provided by the vertical slots 23 in thelugs. The member 24 may be attached to the framework by means of boltand slot connections 27 for in and out adjustment to locate the panel inthe proper vertical plane. The lower lug 21a of the upper panel will fitlaterally between the pair of upper lugs 21 on the lower panel asindicated best in FIG- URE 5. Thus, the panel can be accuratelypositioned on the supporting frame structure. However, in some cases itmay be desirable to weld the lugs 21 or 21a to the building frame.

The panels 20 are preferably so formed that adjacent side edges ofadjacent panels, disposed in side-by-side relationship, can interlock. Asuitable arrangement for this purpose is illustrated in FIGURES 5 and 6.In forming each panel, preferably the end blocks are of special formwith the aligning blocks at one end forming a vertical groove 30 and thealigning blocks at the other end forming a vertical tenon 31. Thus, thetenon arrangement 31 of one panel will extend into and interfit with thegroove 30 of the adjacent panel, as indicated best in FIGURE 6. Forsealing purposes, a sealing gasket 32 may be provided at the inner faceof the groove 30. Thus, a strong interlocking joint is provided and thisjoint may be sealed weathertight with the gasket.

The panels may be made of bricks 10:: but, as indicated in FIGURE 6a,the bricks of adjacent panels 29a preferably do not interlock but theedges thereof abut with a gasket 32a disposed therebetween. The outeredges of the gaskets may be covered with mortar joints for sake ofappearance. The bricks used in the panel will have aligning, verticalopenings which receive the tie rods or tensile rods 16a. Also, the outersurfaces of the top and bottom courses (not shown) will be grooved forreceiving the ribs of beams similar to the beams 12 but these beams neednot be as wide as those used in the concrete block panels.

When the panels 20 are disposed in superimposed relationship in the sameplane in an end-to-end abutting relationship, as indicated in FIGURE 4,they may be keyed together by means of steel keys 35 of angular crosssection which extend vertically into the upper and lower grooves formedin the beams 12 which face toward each other. The keying members 35 arepreferably made in short, horizontal sections so that they will fitbetween the projecting adjacent rods 16 that carry the nuts 18 and willnot interfere therewith.

In the example shown in FIGURE 8, I have illustrated how the panel 20may be incorporated in a building structure of wooden frameconstruction. In this case, the panel will be the supporting wall andthe securing flanges 21 need not be provided on the beam members 12b.Some of the rods 16b may be extended through a wooden cap member 40. Theroof structure 41 may then be attached to this cap.

The panels described above are of the general type disclosed in mypreviously mentioned copending application, Ser. No. 524,892. In thatapplication, I have disclosed a machine which would be suitable forproducing these panels at a factory or shop. However, other assemblingmachines may be used or the panels may be produced by hand.

It will be apparent from the above description that I provide aprefabricated panel composed of masonry modules or units laid in any ofthe standard styles of courses set in a bonding mortar and clampedbetween two opposed supporting and clamping beams which are connectedtogether by tensile members extending through aligning openings in themasonry modules. The advantages of being able to produce the panel at ashop or plant are obvious. The use of the individual masonry modules orunits is desirable since it is more economical and it is not necessaryto provide the usual heavy cast panels and the panels can be made fromstandard size masonry modules. This use of standard size modules alsofacilitates their use in the building structure.

Various other advantages will be apparent.

Having thus described this invention, what is claimed 1. A prefabricatedmasonry panel formed of individual masonry modules and comprising upperand lower clamping and retaining beams disposed in predeterminedrelationship, a plurality of masonry modules laid in horizontal coursesbetween said beams with set bonding material such as mortar, and tensilemembers connected to said beams for holding them in said predeterminedrelationship; said masonry modules having vertical openings with theopenings in the modules of the various courses being in verticalalignment, said tensile members being elongated members passingvertically through aligning openings and being connected to said beams,each of said beams having a longitudinally extending keying rib formedthereon inwardly adjacent the outer surface of the adjacent outermostcourse of masonry modules, said modules of the adjacent course beingprovided with grooves in longitudinal alignment which receive the keyingrib of the respective beam, each of said beams being of channel form toprovide the keying rib on its inner surface and a groove in its outersurface, said elongated tensile members having threaded end portionswhich project outwardly through openings in the rib into said groove,and clamping nuts threaded on said end portions and disposed within saidgroove, each of said beams having laterally extending clamping flangeson opposite sides of the rib, and attaching lugs projecting laterallyfrom at least one of said flanges.

2. A building structure comprising a plurality of panels with each panelformed of individual masonry modules and comprising upper and lowerclamping and retaining beams disposed in predetermined relationship, aplurality of masonry modules laid in horizontal courses between saidbeams with set bonding material such as mortar, and tensile membersconnected to said beams for holding them in said predeterminedrelationship; said masonry modules having vertical openings with theopenings in the modules of the various courses being in verticalalignment, said tensile members being elongated members passingvertically through aligning openings and being connected to said beams,each of said beams having a longitudinally extending keying rib formedthereon inwardly adjacent the outer surface of the adjacent outermostcourse of masonry modules, said modules of the adjacent course beingprovided with grooves in longitudinal alignment which receive the keyingrib of the respective beam, each of said beams being of channel form toprovide the keying rib on its inner surface and a groove in its outersurface, said elongated tensile members having threaded end portionswhich project outwardly through openings in the rib into said groove,and clamping nuts threaded on said end portions and disposed within saidgroove, each of said beams having laterally extending clamping flangeson opposite sides of the rib; said panels being disposed in edge-to-edgerelationship, with the edges interfitting.

3. A building structure comprising a plurality of panels with each panelformed of individual masonry modules and comprising upper and lowerclamping and retaining beams disposed in predetermined relationship, aplurality of masonry modules laid in horizontal courses between saidbeams with set bonding material such as mortar, and tensile membersconnected to said beams for holding them in said predeterminedrelationship; said masonry modules having vertical openings with theopenings in the modules of the various courses being in verticalalignment, said tensile members being elongated members passingvertically through aligning openings and being connected to said beams,each of said beams having a longitudinally extending keying rib formedthereon inwardly adjacent the outer surface of the adjacent outermostcourse of masonry modules, said modules of the adjacent course beingprovided with grooves in longitudinal alignment which receive the keyingrib of the respective beams, each of said beams being of channel form toprovide the keying rib on its inner surface and a groove in its outersurface, said elongated tensile members having threaded end portionswhich project outwardly through openings in the rib into said groove,and clamping nuts threaded on said end portions and disposed within saidgroove, each of said beams having laterally extending clamping flangeson opposite sides of the rib; said panels being disposed in edge-to-edgerelationship with a sealing gasket between said edges.

4. A building structure comprising a plurality of panels with each panelformed of individual masonry modules and comprising upper and lowerclamping and retaining beams disposed in predetermined relationship, aplurality of masonry modules laid in horizontal courses between saidbeams with set bonding material such as mortar, and tensile membersconnected to said beams for holding them in said predeterminedrelationship; said masonry modules having vertical openings with theopenings in the modules of the various courses being in verticalalignment, said tensile members being elongated members passingvertically through aligning openings and being connected to said beams,each of said beams having a longitudinally extending keying rib formedthereon inwardly adjacent the outer surface of the adjacent outermostcourse of masonry modules, said modules of the adjacent course beingprovided with grooves in longitudinal alignrnent which receive thekeying rib of the respective beam, each of said beams being of channelform to provide the keying rib on its inner surface and a groove in itsouter surface, said elongated tensile members having threaded endportions which project outwardly through openings in the rib into saidgroove, and clamping nuts threaded on said end portions and disposedwithin said groove, each of said beams having laterally extendingclamping flanges on opposite sides of the rib; said panels beingdisposed in edge-to-edge relationship with the beams of adjacent panelsin contact and with their respective grooves facing toward each other,and a keying member of angular form disposed in said facing grooves.

5. A structure according to claim 4 in which the keying member isdivided into longitudinal sections disposed between adjacent cooperatingtensile member end portions and nuts in said grooves.

6. A structure according to claim 1 in which said lugs comprise a pairof laterally spaced flanges on the beam at one end of the panel and asingle lug on the beam at the other end of the panel located laterallyintermediate the lugs of said pair.

References Cited UNITED STATES PATENTS 1,960,575 5/1934 Davison 52-5871,970,309 8/1934 Hoyer 52-434 2,040,578 5/1936 Venzie 52434 2,874,812 2/1959 Clevett 52227 3,112,578 12/1963 Rosenfeld 52-241 3,248,836 5/ 1966Monk 52-235 HENRY C. SUTHERLAND, Primary Examiner.

